Enhancing drilling accuracy and surface quality in carbon fiber/SiC hybrid composites through taguchi-based parameter optimization

• Optimized drilling parameters enhance CFRP/SiC composite hole quality and structural integrity. • Higher feed rates increase thrust force, while higher spindle speeds reduce it significantly. • SEM analysis confirms improved fiber-matrix adhesion and enhanced mechanical properties. • Delamination and surface roughness depend on feed rate, spindle speed, and tool type. • Proper cutting conditions minimize defects and improve hybrid joining in aerospace applications. This study meticulously investigates the machinability of Carbon Fiber Reinforced Plastic (CFRP) composites with the aim of optimizing drilling parameters for aerospace applications, where mechanical fastening is imperative yet often undermines structural integrity due to stress concentration. A Design of Experiments (DOE) methodology was employed to scrutinize the effects of feed rate (10, 20, 30 mm/min) and spindle speed (500, 1000, 1500 rpm) on drilling performance. The introduction of silicon carbide reinforcement was assessed to determine its influence on hole quality. The optimized drilling parameters markedly enhanced the integrity of holes in CFRP composites. Furthermore, the incorporation of silicon carbide reinforcement significantly elevated drilling performance, mitigating defects typically associated with composite machining. The significance of these findings provides critical guidelines for refining mechanical fastening processes in aerospace applications, where the quality of holes directly influences joint reliability and the structural performance of hybrid joining systems.